Repetitive Upsetting Extrusion Process of Al 5452 Alloy: Finite Element Analysis and Experimental Investigation

Document Type : Research Paper

Authors

Faculty of Materials and Metallurgical Engineering, Semnan University, Semnan, Iran

Abstract

In the last decade, the repetitive upsetting-extrusion (RUE) process has proved its potential in the bulk metal forming process in several investigations on severe plastic deformation (SPD) processes. The RUE process is currently being used to process bulk materials through grain refinement and consequently reaching better mechanical properties such as high strength and high toughness. Different process parameters affect the RUE process and the quality of the processed specimens. In the present investigation, the finite element analysis was carried out by using ABAQUS/CAE software to study the effect of die design on the RUE process, to find the minimum extrusion ratio for processing the Al 5452 alloy using the RUE process and determine the perfect height for the deformation zone in the RUE die. To that end, four cycles of successive RUE were performed on the Al 5452 alloy in the designed die. Microhardness distribution of the processed specimens was found to be more homogeneous and, by raising the RUE cycles, the average microhardness value in the processed specimens increased from 71.5 Hv (Non-cycle RUE processed specimen) to 145.1 Hv (specimen processed by 4 RUE cycles). It was also found that, by augmenting the RUE cycles, the compressive yield stress of the processed specimen increased from 136.622 MPa (Non-cycle RUE processed specimen) to 432.221 MPa (specimen processed by 4 RUE cycles).

Keywords

References

[1] E. Bagherpour, M. Reihanian, N. Pardis, R. Ebrahimi, Ten years of severe plastic deformation (SPD) in Iran, part I: Equal-channel angular pressing (ECAP), Iranian Journal of Materials forming, 5(1) (2018), 71-113.
[2] E. Bagherpour, N. Pardis, M. Reihanian, and R. Ebrahimi, An overview on severe plastic deformation: research status, techniques classification, microstructure evolution, and applications, The International Journal of Advanced Manufacturing Technology, (2019), 1647-1694.
[3] M. Nouri, H. Mohammadian Semnani, E. Emadoddin, H.S. Kim, Investigation of direct extrusion channel effects on twist extrusion using experimental and finite element analysis, Measurement., (2018), 115-123.
[4] R.Z. Valiev, A. V. Korznikov, A. V., R. R. Mulyukov, Structure and properties of ultrafine-grained materials produced by severe plastic deformation, Materials Science and Engineering A (1993), 141-148.
[5] R.Z. Valiev, V. I. Alexandrov, Nanostructured materials from severe plastic deformation, Nanostructured Materials, (1999) 35-40.
[6] J. Wongsa-Ngam, M. Kawasaki, T.G. Langdon, A comparison of microstructures and mechanical properties in a Cu–Zr alloy processed using different SPD techniques, Journal of Materials Science, (2013) 4653-4660.
[7] R.Z. Valiev., R.K. Islamgaliev, I.V. Alexandrov, Bulk nanostructured materials from severe plastic deformation, Progress in Materials Science, (2000) 103-189.
[8] A.P. Zhilyaev, G.V. Nurislamova, B.K. Kim, M.D. Baro´, J.A. Szpunar, T.G. Langdon, Experimental parameters influencing grain refinement and microstructural evolution during high-pressure torsion, Acta Materialia, (2003), 753-765.
[9] M. Nouri, H. Mohammadian Semnani, E. Emadoddin, Computational and experimental studies on the effect back pressure on twist extrusion process, Metals and Materials International, (2020).
[10] R.Z. Valiev, Developing SPD methods for processing bulk nanostructured materials with enhanced properties, Metals and Materials International, (2001), 413-420. 
[11] A. Azushima, R. Kopp, A. Korhonen, D.Y. Yang, F. Micari, G.D. Lahoti, A.Yanagida, Severe plastic deformation (SPD) processes for metals, CIRP Annals, (2008), 716-735.
[12] J. Zrnik, S.V. Dobatkin, I. Mamuzić, Processing of metals by severe plastic deformation (SPD)-structure and mechanical properties respond, Journal Metalurgija, (2008), 211-216.
[13] R.Z. Valiev, Y. Estrin, Z. Horita, T.G. Langdon, M. J. Zechetbauer, Y.T. Zhu, Producing bulk ultrafine-grained materials by severe plastic deformation, JOM, (2006), 33-39.
[14] K. Edalati, M. Ashida, Z. Horita, T. Matsui, H. Kato, Wear resistance and tribological features of pure aluminum and Al–Al2O3 composites consolidated by high-pressure torsion, Wear, (2014), 83-89.
[15] Y. Huang, T.G. Langdon, Advances in ultrafine-grained materials, Materials Today, (2013), 85-93.
[16] P. Bazarnik, Y. Huang, M. Lewandowska, T.G. Langdon, Structural impact on the Hall-Petch relationship in an Al–5Mg alloy processed by high-pressure torsion, Materials Science and Engineering A, (2015), 9-15.
[17] S. Ghaemi Khiavi, E. Emadoddin, Microhardness distribution and finite element method analysis of Al 5452 alloy processed by unconstrained high-pressure torsion, Journal of Materials Research and Technology, (2018), 410-418.
[18] A. Zhilyaev, T.G. Langdon, Using high-pressure torsion for metal processing: Fundamentals and applications, Progress in Materials Science, (2008), 893–979.
[19] I. Balasundar, T. and Raghu, On the die design for Repetitive upsetting - extrusion (RUE) process, International Journal of Material Forming, (2011), 289-301.
[20] Patil, D. C., Kallannavar, V., Bhovi, P. M., Kori, S. A., and Venkateswarlu, K., Finite element analysis of ECAP, TCAP, RUE and CGP processes, IOP Conference Series: Materials Science and Engineering( 2016).
[21] I. Balasundar, T. Raghu, Deformation behaviour of bulk materials during repetitive upsetting-extrusion (RUE), International Journal of Material Forming, (2010), 267-278.
[22] I. Balasundar, T. Raghu, Strain softening in oxygen free high conductivity (OFHC) copper subjected to repetitive upsetting-extrusion (RUE) process, Materials Science and Engineering A, (2013), 114-122.
[23] H. Lianxi, L. Yuping, W. Erde, Y. Yang, Ultrafine grained structure and mechanical properties of a LY12 Al alloy prepared by repetitive upsetting-extrusion, Materials Science and Engineering A, (2006), 327-332.
[24] I. Balasundar, T. Raghu, Investigations on the extrusion defect – Axial hole or funnel, Materials & Design, (2010), 2994-3001.
[25] L. Zaharia, R. Comaneci, R. Chelariu, D. Luca, A new severe plastic deformation method by repetitive extrusion and upsetting, Materials Science and Engineering A, (2014), 135-142.
[26] I. Balasundar, T. Raghu, Severe plastic deformation (SPD) using a combination of upsetting and extrusion, International Journal of Metallurgical Engineering, (2013), 130-139.
[27] B. Binesh, M. Aghaie-Khafri, RUE-based semi-solid processing: Microstructure evolution and effective parameters, Materials & Design, (2016), 268-286.
[28] W. Gao, J. Xu, J. Teng, Z. Lu, Microstructure characteristics and mechanical properties of a 2A66 Al–Li alloy processed by continuous repetitive upsetting and extrusion, Journal of Materials Research and Technology, (2016), 2506–2515.
[29] G. Zhang, Z. Zhang, Y. Du, Z. Yan, X. Che, Effect of isothermal repetitive upsetting extrusion on the microstructure of Mg-12.0Gd-4.5Y-2.0Zn-0.4Zr alloy, Materials, (2018), 2092-2100.
 
Iranian Journal of Materials Forming
Volume 8, Issue 1 - Serial Number 1
January 2021
Pages 65-74

Files

Share

How to cite

Statistics